Shipping container and support dunnage

ABSTRACT

A shipping container and dunnage supports includes at least one first support and at least one second support which are disposed within a shell and are engagable with a peripheral edge of an article disposed within the shell. The first and second dunnage supports may include an insert block positioned in the support to increase the structural and shock absorption characteristics of the support.

CROSS-REFERENCE TO CO-PENDING APPLICATION

[0001] This application is a continuation-in-part application ofco-pending application Ser. No. 10/340,054 filed Jan. 10, 2003 whichclaims the benefit of priority of the Jan. 10, 2002 filing date of U.S.provisional patent application serial No. 60/347,432, the contents ofwhich are incorporated herein in their entirety.

BACKGROUND

[0002] Shipping containers for articles, workpieces, auto parts, etc.,take a variety of shapes and configurations based on the size and shapeof the article or part to be transported. For example, automotive parts,such as vehicle sheet metal parts, i.e., hoods, deck lids, fenders, doorpanels, widow glass, etc., come in numerous shapes.

[0003] One type of shipping container for transporting single articles,such as automotive parts, is a corrugated cardboard box having foldedover panels which are taped or otherwise secured in a closed position.

[0004] As many automotive parts have a Class A surface finish, extraprotection is required to prevent damage to the Class A finish on one ormore surfaces of the part by protecting the Class A finish surface ofthe part from contact with the shipping container itself.

[0005] In the shipping container field, it is known to utilize dunnageto protect articles or parts in shipping containers from movement aswell as from contact with the container. Such dunnage typically takesthe form of foamed plastic blocks or members which are configured withopenings for mounting on one edge of the article or part. The dunnage isdesigned for a snug fit within the shipping container or is fixed inplace by means of adhesive, fasteners, etc., to prevent dislodgement andto prevent movement of the article during shipping.

[0006] Although in certain applications, the dunnage, after the part isremoved from the shipping container, is returned to the manufacturingfacility for reuse. More frequent, the dunnage is removed from theshipping container after the part is removed and then discarded. In thissituation, the dunnage represents an added cost to the article orworkpiece since new dunnage is required for each article or part.

[0007] It would be desirable to provide a shipping container and supportdunnage which adequately supports and protects an article or workpiecedisposed within the shell during storage and shipping, enables easyclosure of the shipping container after the article or workpiece isinserted into the container, reduces the number of dunnage pieces whichcome in contact with or are needed to support the article, increases thestructural characteristics, impact strength or shock absorptionproperties of the dunnage, simplifies the shell of the container andrequires a minimal amount of disposable dunnage to reduce the totalarticle manufacturing cost. It would further be desirable to providedunnage having the above benefits which satisfies the rigorous testingrequirements of industrial manufacturers including automobilemanufacturers.

SUMMARY

[0008] The present invention is a shipping container and dunnage whichprovides advantages over prior article shipping containers and dunnage.

[0009] In one aspect of the invention, the shipping container includes ashell including a plurality of panels which can include a base panel, atop panel and opposed side panels. At least one first support is adaptedto mount over a peripheral edge of an article to support the articlewithin the shell. The first support has a generally C-shape formed oftwo spaced side legs resiliently extending from one end leg. At leastone second support is mounted or positioned within the shell inengagement over a peripheral edge of the particle. The second supporthas an inner channel opening. The channel is configured for mountingover a corner of a peripheral edge of the article.

[0010] In another aspect, the first support is movably disposed withinthe shell. The second pair of supports are fixedly mounted within theshell.

[0011] In another aspect, indicia means are provided on the exteriorsurface of the shell to facilitate to optimum positioning of a bandingstrap about the shell.

[0012] In another aspect, the shipping container includes a shell havinga bottom panel, opposed side panels, each contiguous with one of thebottom panel along a foldable edge, and opposed top panels contiguouswith the side panels about a foldable edge. The top panels are foldableinto overlapping relationship. A first pair of supports is adapted tomount over a peripheral edge of an article to support the article withinthe shell. The first pair of supports have a generally C-shape formed oftwo side legs resiliently extending from one end leg. A second pair ofsupports is fixedly mounted within the shell. Each of the second pairsof supports has an inner channel opening through one side of thesupport. The channel is configured for mounting over a corner formed ina peripheral edge of the article.

[0013] In another aspect, the invention is a support block engagablewith an article for supporting the article in a shipping container. Theblock can be the above described C-shaped block, or the block with aninner recess or any combination thereof.

[0014] In one aspect, the at least one first support includes a singlefirst support and the at least one second support includes a pair ofsecond supports. In another aspect, the shipping container and dunnageblocks are configured to support and protect and automobile hood.

[0015] In another aspect, the invention is at least one support ordunnage block having an insert block positioned in the dunnage block toincrease the structural integrity and impact absorption properties ofthe dunnage block. In another aspect, the dunnage block is made frompolyurethane, polypropylene, polyethylene or any combination thereof Inanother aspect, the support or dunnage block is made from polyurethaneand the insert block is made from polypropylene.

[0016] The present shipping container and dunnage support providesoptimum protection for an article disposed within the container, enableseasy closure of the container after the article is inserted into thecontainer and, further, utilizes a minimal amount of disposable dunnageto reduce the total article manufacturing cost.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The description herein makes reference to the accompanyingdrawings wherein like reference numerals refer to like parts throughoutthe several views, and wherein:

[0018]FIG. 1 is a partial perspective view of one aspect of the shippingcontainer showing an automotive hood positioned in the container;

[0019]FIG. 2 is a top view of the shipping container in FIG. 1 in apartially assembled position;

[0020]FIG. 3 is a perspective view of a first support shown in FIG. 1;

[0021]FIG. 4 is a perspective view of a second support shown in FIG. 1;

[0022]FIG. 5 is a front view of the partially assembled shippingcontainer in FIG. 1 showing the side panels and the first and second toppanels in an angularly displaced orientation to the bottom panel;

[0023]FIG. 6 is a perspective view of the shipping container in FIG. 1in an assembled position;

[0024]FIG. 7 is a perspective view of an alternate shipping containerhaving support dunnage and an automotive hood positioned therein;

[0025]FIG. 8 is a partially cut-away perspective view of an alternatefirst support shown in FIG. 7 including a single first support showingone of the preferred insert blocks;

[0026]FIG. 9 is a left side view of the single first support in FIG. 8;

[0027]FIG. 10 is a rotated, partially cut-away perspective view of thesingle first support in FIG. 8 showing the preferred dual insert blocks;

[0028]FIG. 11 is a rotated perspective view of the single first supportin FIG. 8 including a panel attached thereto;

[0029]FIG. 12 is a perspective view of an alternate second support shownin FIG. 7;

[0030]FIG. 13 is a perspective view of a preferred insert block for thesecond support shown in FIG. 12;

[0031]FIG. 14 is a schematic perspective view showing the insert blockof FIG. 13 positioned in the second support of FIG. 12; and

[0032]FIG. 15 is a partial top view of the shipping container shown inFIG. 7.

DETAILED DESCRIPTION OF THE INVENTION

[0033] Referring to FIGS. 1-6, one aspect of a shipping container 10 ofthe present invention is illustrated. Referring specifically to FIGS. 1and 2, shipping container 10 includes, by example, a shell 12, a pair offirst or front supports or dunnage blocks 14 and a pair of second orrear supports or dunnage blocks 16. First 14 and second 16 supports areshown supporting an article, for example, an automotive hood 18 as bestseen in FIG. 1.

[0034] Referring to FIGS. 2 and 5, shell 12 includes a substrate 20including a front edge 24, a rear edge 26, a first side edge 27 and asecond side edge 28. The substrate 20 is divided into five sectionsincluding a bottom panel 29, two side panels 44, a first top panel 52and a second top panel 54. The substrate 20 is generally rectangular inshape in an unfolded or unassembled position as shown in FIG. 2 and ismade from die-cut, heavy-duty corrugated cardboard material. It isunderstood that substrate 20 may alternately be any polygonal shape tofit an application and intended contents and may comprise multiple,non-connected pieces. The substrate 20 may alternately be made fromother materials which include similar physical properties to rigidlycontain articles. As shown in FIGS. 1 and 5, shipping container 10 isdesigned and proportioned to securely support and retain an automotivehood 18. It is understood that the shipping container 10 is adaptablefor other contents or goods without deviating from the presentinvention.

[0035] Referring to FIGS. 2 and 5, bottom panel 29 is generally ofsquare shape and is defined by front edge 24 and rear edge 26 ofsubstrate 20. Bottom panel 29 includes a cutout 30 along both the frontedge 24 and rear edge 26 at the approximate center of bottom panel 29 asseen in FIG. 2. Bottom panel 29 includes a pair of bottom flanges 32that are integral with bottom panel 29 and separated from inner edges 38defining cutouts 30. Bottom flanges 32 include a flange edge 36 defininga length of flange 32 which does not extend beyond the front 24 or rear26 edge of substrate 20 and is preferably distant therefrom. Bottompanel 29 further includes a first crease 34 at the intersection of bothbottom flanges 32 and bottom panel 29. First crease 34 is formed by aslight deforming compression of substrate 20 along a linear path tofacilitate folding or rotating bottom flanges 32 along first crease 34in an angular orientation to bottom panel 29 as best seen in FIG. 5 anddescribed in detail hereinafter.

[0036] The pair of side panels 44 which are separated by and integralwith bottom panel 29. Sides panels 44 are defined by a first side crease46 and second side crease 48 formed in substrate 20 as previouslydescribed. First 46 and second 48 side creases are separated by adistance sufficient to accommodate the height of the desired contentsand supports described below positioned in shipping container 10.

[0037] Substrate 20 further includes a first top panel 52 and a secondtop panel 54 which are integral with the respective side panels 44 asbest seen in FIGS. 2 and 5. The first 52 and second 54 top panelsinclude a second cutout 56 along the front edge 24 and rear edge 26 asbest seen in FIG. 2. First top panel 52 includes a first front flange 58and a first rear flange 59 which are both integral with first top panel52. In a similar fashion to the bottom panel, first top panel 52includes a second crease 62 at the intersections of first front 58 andfirst rear 59 flanges and first top panel 52. The first front 58 and thefirst rear 59 flanges are also separated from an outer edge 64 to permitthe respective flanges to fold or rotate in an angular orientation tofirst top panel 52 as best seen in FIG. 5. First front 58 and first rear59 flanges include a flange edge 66 which is positioned such that therespective flanges do not extend beyond the front edge 24 and rear edge26 as previously described for bottom flanges 32.

[0038] In a similar fashion to first top panel 52, second top panel 54includes a second front flange 60 and a second rear flange 61 which areintegral with second top panel 54. Second top panel 54 similarlyincludes a second crease 62 along the linear intersections of secondfront flange 60 and second rear flange 61 with second top panel 54.Second front 60 and second rear 61 flanges are separated from outer edge64 and include a flange edge 66 similar to that of the first front 58and first rear 59 flanges as previously described. First 52 and second54 top panels are separated from the respective side panels 44 by secondside creases 48 which permit first 52 and second 54 top panels to foldor rotate along second crease lines 48 to angularly displace first 52and second 54 top panels from the respective side panels 44 as best seenin FIGS. 5 and 6.

[0039] It will be understood that the above-described container 10 is byway of example only. The present invention is also usable with othercontainer constructions including a regular slotted carton, afolded-over lap carton or a telescopic carton.

[0040] Referring to FIGS. 1-3 and 5, shipping container 10 preferablyincludes a pair of first supports 14. As best seen in FIG. 3, each frontsupport 14 includes a top surface 80, a bottom surface 82, an outersurface 84, an inner surface 86 and a first or open channel 88. Eachfirst support 14 further includes opposing rounded portions 90 whichpartially obstruct first channel 88 adjacent to inner surface 86. Eachfirst support 14, when used on the side of the component 18, furtherincludes a 45 degree chamfer at the intersections of the top surface 80and bottom surface 82 with the outer surface 84 as best seen in FIG. 3.It is understood that chamfers 92 may be at an alternate angle from 45degrees or may take a rounded or radiused form as opposed to asubstantially flat chamfer as shown.

[0041] First supports 14 may also be positioned on the component or hood18 closer to the center of the front edge of the hood 18. This wouldmove each front support 14 inward toward the opposed front support 14from the side located position shown in FIG. 1. In these so called“front edge” mounted positions of first supports 14, the chamfer 92 willnot be required but may still be used to reduce weight and the amount ofmaterial needed to form the supports.

[0042] It will also be understood that the chamfer 92 for side edgemounted first supports 14 is optional. According to one aspect of theinvention, first supports 14 are formed of a lower density material thanthe rear support 16 described hereafter. This lower density materialallows front supports 14 to absorb external forces better withouttransferring a substantial portion of such forces to the hood 18.

[0043] As best seen in FIGS. 1, 2 and 5, first supports 14 arepositioned on bottom panel 29 adjacent respective first side creases 46and are distant from front edge 24 in an approximate position as shownto accommodate an automotive hood 18. In alternate aspects of theinvention, additional front supports 14 may be used where desired tosupport, for example, less rigid components where needed to furthersupport and protect the contents. First supports 14 are preferably madefrom expanded polyurethane or polypropylene cut or molded to the desiredshape which, in the described configuration, provides both rigidity tosupport hood 18 as well as flexibility to separate rounded portions 90to accept hood 18 and provide a cushion to protect hood 18. Alternatematerials include molded or cut expanded polystyrene and other materialsthat provide rigidity in a block form and substantial cushioning orshock absorption properties while permitting flexibility to insert andremove, for example, an automotive hood 18 into and out of first channel88 as described and illustrated in FIG. 1.

[0044] Referring to FIGS. 1, 2 and 4, shipping container 10 preferablyincludes, for example, a pair of second supports 16. Referring to FIG.4, each rear support 16 has a top surface 102, a bottom surface 104, anouter surface 106, an inner surface 108, a front side 110 and a rearside 112. Each second support 16 further includes an inner channelopening 114 which is partially open to inner surface 108 and includes anundercut 116 substantially as shown. As illustrated, inner channelopening 114 is positioned and oriented in second support 16 to acceptand partially retain a rear corner of an automotive hood 18 as best seenin FIG. 1. Second support 16 further includes a 45 degree chamfer at theintersections of top surface 102 and bottom surface 104 with outersurface 106 and extend the entire length between the front 110 and rear112 sides. It is understood that chamfers 118 may be at an alternateangle from 45 degrees or may take a rounded or radiused form as opposedto a substantially flat chamfer as shown. The second support 16 ispreferably made from expanded polypropylene or polyurethane cut ormolded to the desired shape as substantially shown in FIG. 4. Alternatematerials for second support 16 include those previously described forfirst support 14. As best seen in FIGS. 1 and 2, second supports 16 arepositioned on bottom panel 29 adjacent to the respective first sidecreases 46 and rear edge 26 as substantially shown.

[0045] Referring to the shipping container 10 in FIGS. 1-6, The secondsupports 16 are preferably secured to the shell 12 by a hot melt-typeadhesive 124 which is pre-applied in one or two strips or beads or otherpatterns to surface 104 of the second supports 16 respectively. Thesecond supports 16 are then placed in contact with and disposed onbottom panel 29. Alternate methods to secure second supports 16 to thecontainer 10 include adhesives other than a hot melt-type, double-sidedadhesive tapes and films, or mechanical fasteners such as staplesthrough substrate 20 into the supports 14 and 16.

[0046] Referring to FIGS. 7 and 15, second supports 200 are not mountedto shell 250 but are moveable within shell 250. In an installed positionin shell two, and on installation of the article, for example hood 18,second supports abut opposing side panels 264 and end panel 266 of theshell lower portion 260

[0047] Referring to FIGS. 1, 2 and 5, an automotive hood 18 is mountedin the first supports 14 and second supports 16. The rear corners ofhood 18 are positioned in inner channel 114 and more particularly inundercut 116, and the forward, outer edges of hood 18 are positioned inopen channel 88 in first supports 14 and are preferably in contact withrounded portions 90 to positively locate and retain hood 18 from lateralmovement relative to bottom panel 29. Following installation of hood 18in shipping container 10, bottom flanges 32 on bottom panel 29 arefolded or rotated about first creases 34 to angularly displace bottomflanges 32 with respect to bottom panel 29 to an approximatelyperpendicular orientation as best seen in FIG. 5. The first front 58 andfirst rear 59 flanges on first top panel 52 are similarly displaced in aperpendicular orientation along second creases 62. Second front 60 andsecond rear 61 flanges of second top panel 58 are also displaced at anangular orientation of approximately 90 degrees to second top panel 54in a similar manner. At this stage of assembly, the two beads ofadhesive 124 that were pre-applied on top surface 102 of rear supports16, are revealed through removal of contact or release paper, not shown,to expose the adhesive as shown in FIGS. 1-4.

[0048] As best seen in FIGS. 5 and 6, side panel 44 adjacent to secondtop panel 54 is rotated about first side crease 46 until side panel 44is approximately 90 degrees with respect to bottom panel 29. In thisposition, side panel 44 is directly adjacent to or in slight contactwith outer surfaces 84 and 106 of front supports 14 and rear supports 16supports. Second top panel 54 is then rotated or folded along secondside crease 48 to angularly displace second top panel 54 atapproximately 90 degrees with respect to side panel 44 thereby placingsecond top panel 54 in opposing and substantially parallel orientationto bottom panel 29 as best seen in FIG. 6. In this position, secondfront 60 and second rear 61 flanges are positioned toward the inside ofthe container with respect to bottom flanges 32 of bottom panel 29. Inthis position, adhesive 124 on rear supports 16 adjacent to second toppanel 54 is compressed against second top panel 54 thereby securingsecond top panel 54 to the rear supports 16 and bottom panel 29. Tofacilitate easy angular rotation of side panel 44 and second top panel54 with respect to bottom panel 29, chamfers 92 (optional) and 118 offront 14 and rear supports 16 respectively are utilized to accommodatevariances in substrate 20 and variances in first 46 and second 48 sidecreases both in position of the creases and radii of the creases whenfolded. Chamfers 92 (optional) and 118 further accommodate varianceswith respect to the variable positioning or the supports 14 and 16.

[0049] First top panel 52 and side panel 44 are similarly displaced inangular orientation to bottom panel 29 along first 46 and second 48 sidecreases at approximately 90 degree angles to position first top panel 52in overlapping relation to second top panel 54 and in opposing andparallel orientation to bottom panel 29 as best seen in FIG. 6. In thisposition, adhesive 124 on the exposed top surfaces 102 of and rearsupports 16 adjacent to first top panel 52 is compressed against firsttop panel 52 thereby securing first top panel 52 in this positionsimilar to second top panel 54 as previously described. In thisposition, first front 58 and first rear 59 flanges are positionedbetween bottom flanges 32 of bottom panel 29 and second front 60 andsecond rear 61 flanges forming three thicknesses of substrate 20 inoverlapping orientation to deter movement of automotive hood 18 alongopen 88 and inner 114 channels.

[0050] Referring to FIG. 6, shell 12 optionally further includesmarkings or text 128 (shown in phantom) on the outer surface ofsubstrate 20 to guide a user in applying strapping bandscircumferentially around shipping container 10 to maintain the flanges32, 58, 59, 60 and 61 in an approximately 90 degree orientation to thetop and bottom panels to prevent unwanted longitudinal movement ofautomotive hood 18 with respect to bottom panel 29 and to preventfurther angular disposition of side panels 44 or matchboxing of theassembled shipping container 10. As shown in FIG. 6, in a fullyassembled position, through openings 126 exist which provide a free flowof air and circulation in shipping container 10 and around the contents,for example, automotive hood 18. Adhesive 124 on the front and rearsupports 14 and 16 prevent the supports 14 and 16 from dislodging fromthe hood 18 and inadvertently exiting the shipping container 10.

[0051] Referring to FIGS. 7-15, an alternative shipping container 10 andsupport or dunnage blocks 140 and 200 of the present invention areillustrated.

[0052]FIG. 7 shows a shipping container 10 including a single firstsupport or dunnage block 140, a pair of second supports or dunnageblocks 200 and an alternate shell 250 having a bottom portion 260 and acover portion 270.

[0053] Referring to FIGS. 7 and 15, an alternate shell 250 isillustrated. Shell 250 includes a bottom portion 260 having a generallyrectangular bottom panel 262, opposing side panels 264 and an end panel266 continuous with bottom panel 262. Shell 250 further includes a topcover portion 270 having a complimentary top panel 272, opposing sidepanels 274 and an end panel 276 continuous with top panel 272.

[0054] Top cover portion 270 is sized and configured such that whenrotated about end panel 266 and positioned over bottom portion 250,down-folded side panels 274 and end panel 266 overlappingly engageupturned bottom portion side panels 264 thereby enclosing article 18within shell 250. The cover portion 270 is secured in place by flange278 attaching to the underside of bottom panel 262 (not shown). As withshell 12, shell 250 is exemplary only and can be any polygonal shape,configuration and material suitable for the desired article and dunnagesupports to be used therewith to be shipped or stored.

[0055] Referring to FIGS. 7-11, an alternate first support or dunnageblock 14 may comprise a single first support 140. Single first support140 is preferably positioned along the front peripheral edge of thearticle, for example, hood 18, at the approximate center of the hood asshown in FIG. 7. As best seen in FIGS. 8 and 9, first support 140includes a top surface 142, bottom surface 144, an inner surface 146,outer surface 148 , and opposing sides 150. First support 140 includes afirst leg 154 and second leg 156 both extending from an end leg 158 asbest seen in FIG. 8.

[0056] First leg 154 and second leg 156 define an open channel 162including an angled first portion 164 and second portion 166 whichintersect as shown in FIGS. 8 and 9.

[0057] Second portion 166 preferably includes a step 168 adjacent theintersection. Open channel 162, angled first portion 164, second portion166 and step 168 are configured to mount over a portion of a peripheraledge of, for example, hood 18 as shown in FIG. 7.

[0058] Referring to FIG. 8, first support 140 preferably includes afirst groove 172 positioned on inner surface 146 of second leg 156.First groove 172 includes 45° slanted surfaces 175 intersecting an innerface 176. In use with an automotive hood 18, first groove 176 isconfigured and positioned to accept the hood latch (not shown) of hood18 and further function to deter lateral movement of the hood 18 withrespect to center support 140. It is understood that first groove 172may take different shapes, forms suitable for acceptance of latches,hardware and other features of the article disposed in shell 250.

[0059] First support 140 preferably includes a second groove 180including 45° slanted surfaces 182 intersecting an inner surface 184 aswell as 45° chamfers 186 as best seen FIG. 8. These features areprimarily for reductions in weight and in the material needed tomanufacture the support while maintaining the desired structural andimpact absorption properties. It is understood that second groove 180and chamfers 186 may take other shapes and forms suitable for theapplication or may be eliminated altogether.

[0060] Referring to FIG. 11, first support 140 preferably includes apanel 194 mounted to the outer surface 148 of first support 140. Panel194 is configured to assist in the positioning of first support 140 inshell 250 and deters lateral movement of support 140 in shell 250. Panel194 is made from corrugated cardboard and has a crease 196 providing forcontrolled bending or distortion of the panel 194 for positioning andstability purposes. Panel 194 may be mounted to first support 140 bygluing, taping, stapling, staking or other suitable means.

[0061] First support 140 is preferably made from expanded polyurethanecut or molded to the desired shape having a density in the range fromabout 1.5 lbs/ft³ to 3.0 lbs/ft³. In a most preferred aspect, thepolyurethane density is from about 2.1 lbs/ft³ to about 2.8 lbs/ft³. Asuitable but exemplary polyurethane foam for first support 140 isINSTPAK G-FLEX foam manufactured by Sealed Air Corporation. In analternate aspect, first support 140 can be made from expandedpolypropylene cut or molded to the desired shape having a density in arange from about 1.8 lbs/ft³ to 3.2 lbs/ft³. When polypropylene is usedfor support 140, the most preferred density is from about 2.5 lbs/ft³ toabout 3.1 lbs/ft³. A suitable but exemplary polypropylene for support140 is manufactured by BASF under the trademark NEOPOLEN P in thedensities described above.

[0062] Referring to FIGS. 8-10, first support 140 includes two firstinsert blocks 192 positioned in end leg 158 as shown. First insertblocks 192 are, for example, polygonal in shape and are made fromexpanded polypropylene cut or molded to the desired shape having adensity in a range from about 1.8 lbs/ft³ to 3.2 lbs/ft³. In a mostpreferred aspect, the polypropylene has a density from about 2.5 lbs/ft³to about 3.1 lbs/ft³. First insert blocks 192 are insert molded intofirst support 140 in the approximate locations in end leg 158 as shown.A suitable polypropylene for insert block 192 is manufactured by BASFunder the trademark NEOPOLEN P in the densities described above. In analternate aspect, insert blocks 192 are made from polytheylene having adensity in a range from about 2 lbs/ft³ to about 9 lbs/ft³

[0063] In a most preferred aspect, support 140 is made from polyurethaneand insert blocks 192 are made from polypropylene in the most preferreddensity ranges described above.

[0064] It is understood that one or more supports 140 may be used tosupport an article and the placement on the article and the position inshell 250 may vary depending on the application. It is furtherunderstood that a single or additional insert blocks 192 may be used andtheir size, shape and configuration may vary to suit center support 140or first support 14 to suit the application. Referring to FIGS. 7 and12-14, alternate second supports or dunnage blocks 200 are shown. Secondsupport 200 include a top surface 202, bottom surface 204, inner surface206, outer surface 208, a front side 209 and a rear side 210. Secondsupports 200 have an inner channel opening 212, a chamfer 214 and anundercut (not shown) as previously described and illustrated foralternate second support 16. Second support 200 preferably includesthird grooves 216 and chamfers 222 on top 202 and bottom 204 surfaceshaving slanted surfaces 218 and inner surfaces 220 similar to secondgroove 180 and chamfers 186 in center support 140.

[0065] It is understood that third grooves 216 and chamfers 222 may beof different shapes, sizes and orientation then that as shown to suitthe application or eliminated altogether without deviating from thepresent invention. It is also understood that inner channel 212 may alsovary in size, shape and orientation to suit the application. It isfurther understood that a single or additional second supports 200 maybe used to suit the particular application.

[0066] Each second support 200 preferably includes a second insert block224 as shown in FIGS. 13 and 14. Second insert block 224 includes a topsurface 226, bottom surface 228, inner surface 230, outer surface 232and opposing sides 234. Second insert block 224 preferably includes aninner slot 236 which is positioned and configured to accommodate innerchannel 212 of the second support 200 as best seen as assembled in FIG.14. Second insert 224 is preferably made from expanded polypropylene orpolyethylene cut or molded to the desired shape as previously describedfor first insert 192 and is insert molded into second support 200 asshown in FIG. 14. When second insert 224 is used in second support 200,second support 200 is preferably made from polyurethane as previouslydescribed for first support 140.

[0067] It is understood that one or more second inserts 224 may be usedin second support 200 to suit the application or desiredcharacteristics, or as shown in the alternate second support 16, notused at all. It is further understood that different materials otherthan polyurethane, polypropylene or polyethylene and in differentdensities than those described above for the dunnage supports and insertblocks may be used to provide the desired characteristics describedherein without deviating from the present invention.

[0068] In a preferred aspect, first center support 140 having the firstinserts 192 is used together with second supports 200 having secondinsert 224 and shell 250 to comprise a shipping container 10.

[0069] Referring to FIGS. 7 and 15, in an alternate aspect, the article,for example, an automobile hood 18 is positioned in bottom shell portion260 and into inner channels 212 in second supports or dunnage blocks 200and in the open channel 162 in first support or dunnage block 140 assubstantially described above. Shell cover portion 270 is positionedover bottom portion 250 to enclose hood 18 in shipping container 10.Cover portion 270 is secured to bottom portion 250 by strapping, taping,gluing, stapling or other suitable means for shipment and storage.

[0070] In summary, there has been disclosed a unique shipping containerand dunnage supports which are designed for easy closure, optimumarticle support and protection and minimal disposable dunnage for a lowarticle manufacturing cost.

What is claimed is:
 1. A shipping container for an article having aperipheral edge, the shipping container comprising: a shell including aplurality of panels, including at least a base panel, a top panel andopposed side panels; at least one first support adapted to mount over aperipheral edge of an article disposable within the shell, the firstsupport having a generally C-shape formed of a first leg and a secondleg resiliently extending from an end leg; and at least one secondsupport mounted within the shell, the second support having an innerchannel opening through the support, the channel configured for mountingover a portion of a peripheral edge of an article.
 2. The shippingcontainer of claim 1 wherein: the second support is mounted in aninverted position on the shell.
 3. The shipping container of claim 1further comprising: means for fixedly mounting the second support on atleast one of the foldable panels in the shell.
 4. The shipping containerof claim 3 wherein the mounting means comprises: adhesive applied to atleast one of two opposed surfaces of the second support.
 5. The shippingcontainer of claim 1 wherein the first support further comprises:enlarged ends formed on each of the first and the second side legs. 6.The shipping container of claim 1 wherein: the at least one of the firstsupports comprises a pair of first supports each having a surfacedisposed adjacent to one of the side panels of the shell; and achamfered edge formed on a portion of the surface of the at least one ofthe first pair of supports.
 7. The shipping container of claim 6wherein: the chamfered surface is formed at a juncture of one of theside legs and the end leg.
 8. The shipping container of claim 1 wherein:the at least one of the second supports comprises a pair of secondsupports each having a surface disposed adjacent to one of the sidepanels of the shell; and a chamfered edge formed on the surface of theat least one of the second pair of supports.
 9. The shipping containerof claim 8 wherein: the chamfered surface is formed on at least aportion of the surface facing the side panel of the shell.
 10. Theshipping container of claim 1 wherein: the first and second supports areformed of expanded polypropylene.
 11. The shipping container of claim 1wherein: the first support is movably disposed within the shell whenengaged with an article disposed within the shell.
 12. The shippingcontainer of claim 1 further comprising: foldable flaps disposed incutouts on the base panel and the top panel between the opposed sidepanels; and indicia means, carried on an exterior surface on at leastone of the top and bottom panels of the shell, for indicating a mountinglocation for a securing strap over the flaps and the top and bottompanels of the shell.
 13. A shipping container for an article having aperipheral edge, the shipping container comprising: a shell having atleast a bottom panel, opposed side panels each contiguous with thebottom panel along a foldable edge, and opposed top panels eachcontiguous with one of the side panels about a foldable edge, the toppanels foldable into overlapping relationship; a first pair of supportsadapted to mount over a peripheral edge of an article disposable withinthe shell, the first pair of supports having a generally C-shape formedof a first leg and a second leg resiliently extending from one end leg;and a second pair of supports mounted within the shell, each of thesecond pair of supports having an inner channel opening through thesupport, the channel configured for mounting over a portion of aperipheral edge of an article.
 14. The shipping container of claim 13wherein: the first pair of supports are movably mounted with respect tothe base panel of the shell; and the second pair of supports are fixedlymounted to the base panel of the shell.
 15. The shipping container ofclaim 13 wherein: the first pair of supports are movably disposedadjacent one edge of the base panel of the shell; and the second pair ofsupports are fixed to the base panel adjacent a different edge of thebase panel.
 16. The shipping container of claim 13 further comprising:each of the first pair of supports having a surface facing one of theside panels of the shell; and a chamfered surface formed on a portion ofthe surface of each of the first pair of supports and disposed adjacentto one of the foldable edges between the side panels, the top panel andthe bottom panel of the shell.
 17. The shipping container of claim 13further comprising: each of the second pair of supports having a surfacefacing one of the side panels of the shell; and a chamfered surfaceformed on a portion of the surface of each of the second pair ofsupports and disposed adjacent to one of the foldable edges between theside panels, the top panel and the bottom panel of the shell.
 18. Theshipping container of claim 13 further comprising: means for fixing thesecond. pair of supports to the bottom panel of the shell; and fasteningmeans, carried on a surface of at least one of the second pair ofsupports opposite from a surface of the second pair of supports fixed tothe bottom panel of the shell, the fastening means engagable with one ofthe top panels when the top panels are overlapped over the second pairof supports.
 19. Support dunnage for use with an article having aperipheral edge disposable in a shell, the support dunnage comprising:at least one first support positioned in a shell having a first leg anda second leg extending from an end leg forming a first open channelconfigured for mounting over a portion of a peripheral edge of anarticle; and at least one second support positioned in the shell distantfrom the first support and having an inner channel opening configuredfor mounting over a portion of the peripheral edge of the article. 20.The support dunnage of claim 19 wherein the at least one first supportcomprises a single first support.
 21. The support dunnage of claim 22wherein the first support further comprises a panel mounted to the firstsupport to position the first support in the shell.
 22. The supportdunnage of claim 19 wherein at least one of the first and the secondsupports includes an insert block positioned in the support.
 23. Thesupport dunnage of claim 25 wherein the first support includes a firstinsert block and the second support includes a second insert block. 24.Support dunnage for use with an article having a peripheral edgedisposable in a shell, the support dunnage comprising: a first supportpositioned in a shell having a first leg and second leg extending froman end leg forming a first open channel configured for mounting over aportion of a peripheral edge of an article disposable within the shell,the first open channel having an angled first top portion intersecting asecond portion having a step adjacent the intersection, the firstsupport further having at least one first insert block positioned in thefirst support; and a pair of opposing second supports positioned in theshell distant from one another and from the first support, each secondsupport having an inner channel opening configured for mounting over aportion of the peripheral edge of the article and each second supporthaving a second insert block positioned in the second support.
 25. Thesupport dunnage of claim 24 wherein the first support comprises a singlefirst support positioned between the second supports and distanttherefrom.
 26. The support dunnage of claim 25 wherein the first supportincludes a panel mounted to the first support to position the support inthe shell.
 27. The support dunnage of claim 24 wherein at least one ofthe first and second supports is made from polyurethane having a densityof about 1.5 lbs/ft³ to about 3.0 lbs/ft³.
 28. The support dunnage ofclaim 24 wherein at least one of the first and second insert blocks ismade from polypropylene having a density of about 1.8 lbs./ft³ to about3.2 lbs./ft³.
 29. A dunnage block for use in supporting and protectingan automobile hood having a peripheral edge positioned in a shell, thedunnage block comprising: a support having a top surface, a bottomsurface, an inner surface and an outer surface, the support having achannel configured for mounting over a portion of a peripheral edge ofan automobile hood.
 30. The dunnage block of claim 29 wherein thesupport further comprises a first leg and a second leg extending from anend leg and wherein the channel is a first open channel.
 31. The dunnageblock of claim 30 further comprising an enlarged end distant from theend leg on at least one of the first leg and the second leg.
 32. Thedunnage block of claim 30 wherein the first open channel furthercomprises an angled first channel portion and a second channel portionintersecting the first portion defining the first open channel.
 33. Thedunnage block of claim 32 wherein the second channel portion furthercomprises a step adjacent the intersection of the second channel portionand the first channel portion.
 34. The dunnage block of claim 30 furthercomprising a first insert block positioned in the support.
 35. Thedunnage block of claim 30 further comprising a panel mounted to thesupport to position the support in the shell.
 36. The dunnage block ofclaim 30 wherein the support further comprises a first groove positionedon an inner surface of at least one of the first and the second legs.37. The dunnage block of claim 29 further comprising a front side and anopposing rear side and wherein the channel is an inner channel openingin the front side and inner surface of the support.
 38. The dunnageblock of claim 37 wherein the inner open channel further comprises anundercut portion extending toward the rear side of the support.
 39. Thedunnage block of claim 37 further comprising a second insert blockpositioned in the support.
 40. The dunnage block of claim 29 furthercomprising a chamfer on the outer surface of the support adjacent atleast one of the top surface and the bottom surface.
 41. The dunnageblock of claim 29 further comprising an insert block positioned in thesupport, the support having a first composition and the insert having asecond composition.
 42. The dunnage block of claim 41 wherein the firstcomposition is selected from the group consisting of polyurethane andpolypropylene.
 43. The dunnage block of claim 42 wherein the firstcomposition is polyurethane having a density of from about 1.5 lbs/ft³to about 3.0 lbs/ft³.
 44. The dunnage block of claim 42 wherein thefirst composition is polypropylene having a density of from about 1.8lbs/ft³ to about 3.2 lbs/ft³.
 45. The dunnage block of claim 41 whereinthe second composition is selected from the group consisting ofpolypropylene and polyethylene.
 46. The dunnage block of claim 45wherein the second composition is polypropylene having a density of fromabout 1.8 lbs/ft³ to about 3.2 lbs/ft³.
 47. The dunnage block of claim45 wherein the second composition is polyethylene having a density offrom about 2 lbs/ft³ to about 9 lbs/ft³.
 48. The dunnage block of claim41 wherein the first composition and the second composition are ofpolypropylene having a density of from about 1.8 lbs/ft³. to about 3.2lbs/ft³.